Ensuring that the performance, efficiency and drivability of your e-drive perfectly matches the vehicle requires extensive testing and optimization. The AVL E-Motor TS™ Performance system, including software packages and ready-to-use applications, allows you to quickly develop, test and validate your e-drive to the highest quality standards.
Our system serves as a comprehensive environment for the development, testing, verification and validation of electric drives, focusing on electrical, mechanical and thermal characteristics. With our proven software toolchain, it optimizes electric drives for maximum efficiency and NVH performance. The AVL E-Library enhances the validation process with automated test reporting, while ISAC and VSM offer precise tuning and validation for real-world vehicle operation.
To stay ahead of future developments, our standard AVL E-Motor TS™ Performance solution includes a high-speed capability of 25,000 rpm. We offer a range of additional features to enhance your e-drive testing and optimization:
- AVL PUMA™ Automation System: Facilitates automation, simulation, real-time processing, data recording, and storage, among other functions.
- AVL CAMEO™: Specialized for optimizing e-drives.
- Dyno and Mechanics: Designed for high-speed and high-torque applications.
- Modern SiC Dyno Control Cabinet: Provides optimal control performance.
- High-Accuracy E-STORAGE Battery Emulator: Ensures precise battery emulation.
- AVL X-ion™ Power Analyzer: Includes the e-Power toolbox for various applications.
- AVL Universal Inverter: Supports e-motor development and tuning.
- Climatic Chamber and Coolant Conditioning Unit: For performing climatic tests.
- AVL Dynamic Torque Transducer: Analyzes e-drive NVH, optimizes control, and enhances simulation accuracy.
This comprehensive suite of features ensures that your e-drive testing and development are future-proof and of the highest quality.
| Technical Details | |
|
AVL PUMA 2™ |
E-motor GUI, 10kHz realtime system, |
|
Dynamometer |
Speed 25,000 rpm, torque up to 1200 Nm |
|
E-STORAGE™ SiC |
1200 V |
|
SPECTRA™ Universal Inverter |
switching frequency 2 – 96 kHz, |
|
AVL X-ion™ |
up to 12 Msamples, NVH measurements, |
|
Coolant conditioning system |
–40 to 130 °C |
|
Climatic chamber |
–40 to 150 °C |
|
Dynamic Torque Transducer |
± 3,500 Nm | 25 kHz | 0.5 % accuracy |
AVL SPECTRA™ Dyno PMM
High-performance e-drive systems are moving towards greater power density and compact design, requiring higher speed and dynamics. OEMs need to offer e-drive systems across various speed, power, and torque ranges. This demands a dynamometer that balances high-speed, high-torque performance with excellent dynamics. The AVL SPECTRA™ Dyno PMM uses SiC technology for precise testing, with a bearing system lasting over 20,000 hours and advanced control features for optimal results.
AVL SPECTRA™ Universal Inverter
As e-drive system development and validation accelerates, testing e-motors and inverters separately before final system tests is essential. A universal inverter is required to validate e-motor performance and dynamics. For realistic results, its control properties must mirror those of the final inverter. The AVL SPECTRA™ Universal Inverter, with advanced SiC MosFET technology, supports diverse switching frequencies and emulates traction inverters, featuring an integrated FPGA control unit for all tasks.
AVL E-STORAGE™
AVL E-STORAGE offers versatile testbed configurations for efficient and resource-conscious testing. From battery testing and emulation to full electrified powertrain evaluations, it provides comprehensive, flexible solutions. As demand for electric powertrains increases, future-proof and adaptable equipment becomes crucial. The AVL E-STORAGE SiC marks a significant advancement in testing technology, offering scalable solutions ranging from 160 kW to multi-megawatt clusters.
AVL X-ion™ e-Power
The AVL X-ion™ integrated power analyzer is designed for advanced testing of advanced and future traction drives. It simplifies setting up e-motor, inverter, and e-drive testbeds with seamless integration into automation and optimization systems. High-performance power analysis provides extensive raw data for post-processing and real-time results. Software features include user-configurable algorithms, real-time results, online streaming, customizable formulas, and rotor position calculations.
AVL PUMA 2™ E-Motor
AVL PUMA is the top choice for e-motor testing, with AVL providing 60% of e-drive test systems globally. Our automation system offers precise speed and rotor position control, vehicle simulation, and a user-friendly interface. Integrated with AVL CAMEO™ and AVL X-ion™, AVL PUMA 2™ E-Motor enables advanced e-motor calibration. It accelerates validation with ready-to-use test cycles and supports two e-motors in a back-to-back configuration, reducing development complexity and time-to-market.
E-Library™ for E-Motor Testing
The E-Library for E-Motor Testing offers functional, characterization, and performance tests aligned with industry standards, enriched by our expertise. This user-friendly application package integrates with the AVL PUMA 2™ E-Motor automation system, providing customizable and ready-to-execute tests. Instant test reports with user-defined data are generated using AVL CONCERTO™ data processing environment, simplifying the testing process.
Media Conditioning Systems
To accurately simulate extreme driving conditions, conditioning systems must create extreme media conditions that are essential for effective testing. Testbed efficiency is improved by quickly establishing initial conditions. Oil and coolant conditioning systems enable rapid cooling of the unit under test at the end of each test cycle, allowing more tests, including cold start tests, to be performed in the same time frame.
E-Motor Climatic Chamber
Our climatic chamber for e-motor testing offers an energy-efficient solution that minimizes chamber space and reduces operational costs while supporting sustainability goals. With a separate air conditioning unit, it allows for precise control of temperature and airflow, ensuring optimal testing conditions for various evaluations. Its compact design facilitates easier installation and maintenance, enhancing cost-effectiveness and versatility.
To truly unlock the potential of electric drive systems, we must embrace the future with unmatched precision and innovation. That's where our cutting-edge technology meets the evolving demands of electric power to deliver exceptional performance and reliability. In this way, we're redefining what's possible in e-motor performance."
– Mario Propst, System Line Manager E-Drive, AVL List GmbH
The AVL E-Motor TS™ Durability is a 4-quadrant e-motor durability test system, operational 24/7.
Validate the electromagnetic compatibility of your electric drive with our specialized test system.
Electrified propulsion systems are a growing part of modern transportation. The changing noise/sound landscape is increasingly demanding modern NVH engineering. At AVL, we have solutions and processes for optimizing the design and quality assurance of interior and exterior vehicle sound.
AVL CAMEO 5™ unlocks a new maturity level of calibration and validation in automotive software testing.
The AVL X-ion™ e-Power power analyzer is a modular data acquisition platform that is optimized for electric and hybrid applications.
The SPECTRA converter system is a modular silicon carbide (SiC) converter able to control wheel dynos at unprecedented levels of control accuracy and dynamics thus helping you to test your powertrain with confidence.
Battery packs, modules and cells, fuel cells, e-motor and e-axle solutions must operate safely and reliably in any environment. This can include extreme temperatures and humidity, which cannot be reproduced on the test track or in real test scenarios on the road. This is why we developed the modular AVL Climate Chamber.
Thermal conditions and environment of Units Under Test have strong impacts on real results in driving. For this reason, the thermal simulation must be as exact as possible – which can be achieved via deployment of high performing media conditioning systems.
The best-in-class automation system for e-motor testing.
The AVL Customer Services organization consists of more than 700 service- and application engineers worldwide, operating from more than 50 locations. Our global footprint is your local benefit.
AVL RACETECH, the motorsport department of AVL, presents the prototype of an innovative H2 internal combustion engine. The power unit is a compact, hydrogen-powered 2-liter turbo engine, with intelligent water injection, which achieves a totally new performance level. The first racing engine that AVL RACETECH is developing and building in-house.
